tefen/industries.asp?pageInstanceId=150

1. Lean Six Sigma Methodology http://www.tefen.com/industries.asp?pageInstanceId=150

2. Attributes of Lean Producers - they • use JIT to eliminate virtually all inventory • build systems to help employees produce a perfect part every time • reduce space requirements • develop close relationships with suppliers • educate suppliers • eliminate all but value-added activities • develop the workforce • make jobs more challenging • reduce the number of job classes and build worker flexibility

3. Waste in Operations • Overproduction • Waiting time • Transporting • Non-value added processing • Inventory • Defects • Underutilized talent Fig. 15.1, p. 686

4. Time Function Map Receive product Order Product Customer Process Order Sales Productioncontrol Order Wait Order Print Plant A Product WIP Wait Wait Wait Warehouse Product WIP Plant B Extrude Product WIP WIP Transport Move Move 12 days 13 days 1 day 4 days 1 day 10 days 9 days 1 day 1 day

5. Production Process Flow Diagram Customer Purchasing (order inks, paper, other supplies) Customer sales representative take order Vendors Prepress Department (Prepare printing plates and negatives) Receiving Accounting Printing Department Warehousing (ink, paper, etc.) Gluing, binding, stapling, labeling Collating Department Information flow Material flow Polywrap Department Shipping

6. 5 WhysExample The Washington Monument is disintegrating.Why? Use of harsh chemicalsWhy? To clean pigeon poopWhy so many pigeons? They eat spiders and there are a lot of spiders at monumentWhy so many spiders? They eat gnats and lots of gnats at monumentWhy so many gnats? They are attracted to the light at dusk.Solution: Turn on the lights at a later time.

7. 5 S Philosophy • Seiri – Sort • Seiton – Set in Order • Seiso – Shine • Seiketsu – Standardize • Shitsuke – Sustain

8. 90 min Initial Setup Time Separate setup into preparation, and actual setup, doing as much as possible while the machine/process is running (save 30 minutes) Step 1 60 min Move material closer and improve material handling (save 20 minutes) Step 2 45 min Standardize and improve tooling (save 15 minutes) Step 3 25 min Use one-touch system to eliminate adjustments (save 10 minutes) Training operators and standardizing work procedures (save 2 minutes) Step 4 Step 4 15 min 13 min Step 5 Steps to Reduce Setup Time

9. Small versus Large Lots JIT produces same amount in same time if setup times are lowered JIT Small Lots C A A B B B C A A B B B Time Small lots also increase flexibility to meet customer demands Large-Lot Approach C A A A A B B B B B B C

10. JIT Reduced Wasteat Hewlett-Packard Waste Reduction (%) Setup Time 20% Scrap 30% Finished Goods Inventory 30% Space 40% Lead Time 50% Raw Material Inventory 50% Work-in-Process Inventory 82% 0% 20% 40% 60% 80% 100%

11. Visible Kanban (Control) Production Move Production Move 1- Card Kanban 2-Card Kanban Visible Kanban

12. JIT Experiential Exercise

13. Kaizen – Continuous Improvement DMAIC Define Measure Analyze Improve Control

14. Kaizen – Continuous Improvement PDSA Plan Do Study Act